So, by now you’re asking—Mallet, what mallet? Really, there is a mallet. Amazing, I could spend 4 sessions showing you how to make a little 2” disk. The good news is, that was the Hard Part. I’m assuming if you’re going to actually make this project, you already have a lathe and know how to use it. If you depend on me to teach you to turn, we’re both in trouble. My experience is rather limited in this area.. That said, you’ll see how basic this part really is.
And now Ladies and Gentleman—-The Mallet!
First, glue up your stock, unless you choose to use a solid piece, which is certainly OK. Again, I had Bubinga left over from a job that was 7/8” thick. I ripped it about 3 1/2”, about 6” long or so. These measurments can vary according to the size you want your mallet. The handle was about 12” long which leaves plenty to trim. The handle layout can be anything you choose. Be creative.
Turn the handle to your liking. Leave a tenon about 2” long and 1” in diameter to glue into the head
Use standard procedures for turning the head. Mine is 3” at the large end. Be sure and coordinate the head with the handle so everything flows.
Drill for the medallion before turning. I found when drilling the hole in the end for the handle, it works much better to start with a smaller hole (3/4” works). work your way up through several sizes. I discovered you can’t drill a 2 1/8” hole in the end grain of Bubinga. Obviously, drill the depth of the thickness of your medallion.
My band saw fence worked well for clamping the head for drilling. See it under my projects.
Turn to desired size and shape.
Drill the other end to accept the tenon on the handle. Be carefull turning the tenon to insure a tight fit. 
Glue pieces together. You can glue the medallion at the same time.
Clean up everything and finish. I used Watco Danish Oil—3 coats. Follow label directions. Finish off with a coat of paste wax. and YOU ARE DONE
I thank you for taking the time to check out my first blog on how to do something. I know the last part rushed through the steps. I didn’t want to totally bore those of you who know way more about turning than I do. If you need any clarification on any part———just ask.
-- Kent Shepherd * The goal is-----More Tools!
17 comments so far
PurpLev
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2764 posts in 547 days
posted 96 days ago
fantastic! thanks for the journey!
-- When in doubt - There is no doubt - Go the safer route.
a1Jim
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17140 posts in 476 days
posted 96 days ago
Weee doggie that was great. Super job kent thanks for sharing.
-- Jim from Heirloom Woodshop, custom furniture ,maker, woodworking school, heirloomwoodshop.com
Loucarb
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962 posts in 344 days
posted 96 days ago
Wow that is really nice. I have been trying to get better on my lathe and this would be a great project. Thanks for sharing.
degoose
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2023 posts in 253 days
posted 96 days ago
Kent I really enjoyed reading every word. Unlike my clumsy attempts at blogs yours flowed smoothly and succinctly. Nicely photographed and well set out. I congratulate you but would I expect anything less from a man who uses Bubinga in his jigs?
Thank your from the bottom of my [vast] woodpile.
Larry from the land downunder.
-- Drink once, cut twice. New website up.... lazylarrywoodworks.com.au
reggiek
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716 posts in 169 days
posted 96 days ago
That looks too good to use!.....nice job…excellent write up….I was thinking of making a new mallet for my newly acquired set of 2 cherry chisels…..(got em used – guy didn’t want to sharpen them…so he bought a cheap set at HD….I even offered to sharpen them up for him….this helped as I didn’t feel too bad for getting them at a steal).
-- Woodworking.....My small slice of heaven!
Kent Shepherd
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840 posts in 185 days
posted 96 days ago
Larry, I like that word—-succinctly—-what does it mean????????
-- Kent Shepherd * The goal is-----More Tools!
reggiek
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716 posts in 169 days
posted 96 days ago
Hehe…it means in a few words…briefly…abruptly or tersely…..
Just in case you aren’t yanking his chain a bit…hehe
-- Woodworking.....My small slice of heaven!
Kent Shepherd
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840 posts in 185 days
posted 96 days ago
reggiek, I was but thanks anyway
-- Kent Shepherd * The goal is-----More Tools!
mtnwild
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2026 posts in 426 days
posted 96 days ago
Well I have not read every word yet, but that is one fine, personalized mallet there! A real craftsman’s tool.
-- mtnwild (Jack), It's not what you see, it's how you see it.
cabinetmaster
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8725 posts in 457 days
posted 96 days ago
Yeppers, Thanks for the blog. Now I must go make me one. You did a fantastic job.
-- Jerry--A man can never have enough tools or clamps
blackcherry
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731 posts in 722 days
posted 96 days ago
Ken you might want to join the folks over at FWW or Popular Woodworking in writing how to articles. Great writing and illustration on this build, I enjoy the blog and thanks for posting…Blkcherry
ratchet
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301 posts in 686 days
posted 96 days ago
Very nice explanation of the build. If you don’t like that mallet then you don’t like wood.
Nice work and thanks for sharing.
Dennis Zongker
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1018 posts in 491 days
posted 95 days ago
Great Blog, Kent. Thanks for posting.
-- Dennis Zongker
Grumpy
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14932 posts in 750 days
posted 94 days ago
Well done Kent. Thanks.
-- Grumpy - "Always look on the bright side of life"- Monty Python
notottoman
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487 posts in 129 days
posted 89 days ago
Fantastic blog. Very informative, easy to follow.
Now to follow the leader.
Thanks Kent.
-- "Even small steps makes a distance." (Shawn Phillips, musician)
patron
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2462 posts in 240 days
posted 89 days ago
kent ,
wonderful mallet ,
and a good blog with the process .
i learned some nice stuff here .
thank you !
and of course when the word BUBINGA ,
appears , larry is sure to follow ,
thats how i get him to look at my projects too (lol )
-- david ,new mexico ,allheart
pommy
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978 posts in 590 days
posted 89 days ago
Wow Kent
she turned ( excuse the pun ) out beautifull been good to follow the journey
Andy
-- cut it saw it scrap it